Papermaking fabric seam and method of making the same

ABSTRACT

A Fourdrinier papermaking belt having porous fabric comprising warp and weft strands and having a porous seam of polymeric filaments and a method of making such seam by interconnecting the end portions of the fabric together to form an endless belt. The method including cutting the warps back into complementary patterns and removing the weft strands from the cut area. Laying a first polymeric replacement weft strand over certain of the exposed warp pickets and moving the adjacent end portions together so that other of the warp pickets ride over the first replacement strand and into abutment with the corresponding cut warps of the other end portion. A plurality of other polymeric replacement weft strands are then woven across respective of the exposed warp pickets to complete the seam area, whereafter, the warp joints are bonded together and the warp and weft strands are bonded to each other at their areas of contact to provide the porous seam.

United States Patent [72] Inventor Laurence D. Kunsman Willoughby, Ohio[21] App1.No. 692,798 [22] Filed Dec. 22, 1967 [45] Patented Nov. 23,1971 [73] Assignee The Lindsay Wire Weaving Company Cleveland, Ohio 54]PAPERMAKING FABRIC SEAM AND METHOD OF MAKING THE SAME 24 Claims, 7Drawing Figs.

[52] US. Cl 156/158, 28/72,156/159,156/258,245/10,162/D1G. 1 [51] 1nt.ClD04h3/l2 [50] Field of Search 162/D1G. l, 348; 139/383, 425.5; 156/502,546, 159, 158, 258; 28/72, 73; 245/10 [56] References Cited UNITEDSTATES PATENTS 3,060,547 10/1962 MacBean r. l62/FFM 3,109,219 11/1963 DeBell et al. 139/4255 3,238,594 3/1966 Schuster 3,366,355 l/l968 HallerABSTRACT: A Fourdrinier papermaking belt having porous fabric comprisingwarp and weft strands and having a porous seam of polymeric filamentsand a method of making such seam by interconnecting the end portions ofthe fabric together to form an endless belt. The method includingcutting the warps back into complementary patterns and removing the weftstrands from the cut area. Laying a first polymeric replacement weftstrand over certain of the exposed warp pickets and moving the adjacentend portions together so that other of the warp pickets ride over thefirst replacement strand and into abutment with the corresponding cutwarps of the other end portion. A plurality of other polymericreplacement weft strands are then woven across respective of the exposedwarp pickets to complete the seam area, whereafter, the warp joints arebonded together and the warp and weft strands are bonded to each otherat their areas of contact to provide the porous seam.

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INVIL'NTOR. LAURENCE D. KUNSMAN ATTORNEYS PAPERMAIKING FABRIC SEAM ANDMETHOD OF MAKING THE SAME BACKGROUND OF THE INVENTION This inventionrelates to porous fabrics, and more particularly relates to a porousseam and method for making the same by interconnecting the end portionsof the fabric to fonn an endless forming structure, such as aFourdrinier-type belt.

A Fourdrinier-type belt, as the term is here used, is the type of beltupon which paper is made in conjunction with paper making machines. Itis generally a woven fabric composed normally of metal warp and shutewires which extend lengthwise and crosswise, respectively. In mostcases, a length of the fabric has its ends joined, wire by wire, bybrazing to provide the seam or joint necessary to make an endless belt.

The type of seam depends upon the mesh of the fabric and the type ofpaper to be made on its surface. Generally, coarse mesh fabrics areformed into belts with woven or sewed seams, although brazed seams havebeen employed in some instances.

The finer mesh metal fabrics are formed into belts almost exclusively bybrazing techniques. Brazing provides a seam which appears as acontinuation of the fabric so as not to cause any difierence in theappearance of the paper made thereon.

Fourdrinier belts woven of metal warp and weft or shute wires have beensatisfactory in many respects, but have caused difficulties because ofthe inherent nature of metals. Generally, metals soft enough to weavesuffer from rapid wear and sustain damaging stresses with some degree ofpermanency of damage. Metals also have a flexing limit at a given stresslevel, commonly known as fatigue life. In addition, metals are subjectto corrosive attack which limits the service life of the belt.

During the past few years, a growing interest has arisen in theapplication of plastic filaments in place of the metal warp and shutewires in the weaving of Fourdrinier-type fabrics, While such plasticfilaments offer some advantage over the metal wires in service, it hasbeen difficult to make woven fabrics into belts by seaming or joiningthe ends thereof. In one such prior application, the ends of the warpfilaments have been flattened or otherwise shaped by swagging and byheat and/or pressure. The shaped ends were then lapped and joinedtogether by an adhesive. In another form the warp and shute filamentswere joined together under heat and pressure, such as by press plates,to provide a solid weld joint across the filaments. In a furtherapplication, the warp filaments have been cut back and the shutesremoved to provide complementary patterns on the warps which are joinedtogether, but wherein specially shaped auxiliary shute filaments weredrawn or pushed through corrugations in the warps to complete the seamarea.

With woven plastic fabrics or semiplastic fabrics, such as plastic warpand metal weft strands, the seam must be strong in tension and flexing,with no objectionable discontinuities in the woven geometry of thefabric. In addition, the seam must have an efficient service life and beeconomical to produce Heretofore known methods have not incorporated allsuch specifications necessary to form an acceptable seam.

Typical of the methods in the prior art are disclosed in the UnitedStates Pat. Nos. to MacBean 3,060,547, DeBell 3,109,219 and Schuster3,238,594.

SUMMARY OF THE INVENTION A porous seam for interconnecting the endportions of a porous fabric having polymeric warp filaments is made bycutting adjacent warp filaments on one of said end portions to differentlengths relative to one another, cutting adjacent warp filaments on theother of said end portions to different lengths relative to one anotherto provide a complementary pattern with respect to the first cut endportion, removing the shute filaments between the cut ends of the warpfilaments so as to expose, the extensions of said warp filaments, layinga polymeric replacement shute filament transversely of the warp filamentextensions and in spaced relation adjacent the nearest remaining shuteelement on one of said end portions, moving said end portions togetherso that the cut ends of the warp filaments of said other end portionride over said replacement shute and into abutting engagement with thecorresponding cut ends of the warp filaments of said one end portion,and then weaving a plurality of other polymeric replacement shutefilaments transversely across the exposed warp filament extensions ofboth of said end portions. The joints between the cut ends of the warpfilament extensions are then bonded together by an adhesive material,and a further adhesive material is applied to saturate the area adjacentthe joints to bond the warp and replacement shute filaments together attheir areas of contact, whereafter, excess adhesive material is removedto provide the finished seam, and then the adhesive subjected to thermalcuring.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary top plan viewof a woven fabric strip with its end portions joined together by theimproved seam construction of the invention;

FIG. 2 is a fragmentary top plan view of the two end portions of thestrip ready to be connected together after the warp filaments have beencut and the shute filaments removed, and with the first replacementshute placed in position;

FIG. 3 is an enlarged fragmentary side elevation view of the endportions of the fabric strip shown in FIG. 2, but illustrating theintended position of the replacement shute filaments on the right handend of the fabric;

FIG. 4 is an enlarged fragmentary side elevation view looking in thedirection of the line 4-4 of FIG. 1;

FIG. 5 is a fragmentary vertical section view taken along the line 5--5of FIG. 4;

FIG. 6 is an enlarged fragmentary section view illustrating one methodof cutting the ends of the warp filaments in accordance with theinvention; and

FIG. 7 is an enlarged fragmentary section view illustrating anothermethod of cutting the warp filaments in accordance with the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawings andin particular to FIG. I, there is illustrated a length of Fourdriniertype fabric, designated generally at F, with the warp filaments beingindicated at l to II and the shute strands or filaments being indicatedat 20 to 36, respectively. In the form shown, the fabric has a plainweave in which an evenly spaced pattern of warps and shutes form aseries of openings therebetween. The warp filaments are shown (FIG. 3)as overlying one shute filament and underlying the next adjacent shutefilament etc., so as to provide a transverse line of knuckles overeve'rgwathershute filament when looking either from the top or bottomside of the fabric.

In FIG. I, the two opposed transverse end portions of the fabric areconnected together by the improved seam, designated generally at S, andmade in accordance with the invention to provide a composite unitarystructure, such as a filter, screen, belt or the like. FIG. 2illustrates one end portion A, such as the right hand, and the other endportion B,

such as the left hand, spaced apart from another and ready to be joinedinto the fabric F, as shown in FIG. 1.

In the main body of the fabric F, the warp filaments, such as I to ill,may be made from a polymeric material while the shute filaments, such as20 to 25 and 31 to 36, may be made tures as may occur in use of thepaper making machine. For filaments comprised of a polyester material,the heat treat- .nent may be carried out at a temperature of about 200F. for about twenty minutes to heat set the fabric.

In forming the seam S, the adjacent ends A and B of the fabric are cut,so that the ends of the warp filaments are trimmed square. Moreover, ifbutted together with edges in perfect alignment, the warp filaments ll-Ato ll-A are substantially parallel and appear to be geometricallycontinuous with the warp filaments 1-8 to l1-B, as best seen in FIGS. 1and 2.

After the end portions A and B of the fabric have been cut, the warpfilaments of each of the respective portions are cut back and the shutesremoved in accordance with a predetermined pattern, such as shown inFIG. 2. In one form, this may be accomplished by cutting alternate warpfilaments on each end portion so that 3 or more shutes lie transverselybetween the cut and the adjacent terminal edge of the fabric. Forexample, the cutting may proceed in end portion A by cutting warpfilaments l-A, 3-A, -A, 7-A, 9-A, etc., in one plane extendingtransversely of the fabric, and by cutting adjacent warp filaments 2A,4-A, 6-A, 8-A, l0-A, etc. in another plane extending transversely of thefabric. After such pattern is cut, the shute filaments within thismarginal area are removed so as to form the warp pickets shown in FIG.2. This sequence of cutting the warp filaments and removal of the shutefilaments is similarly carried out with respect to the adjacent endportion B. Preferably, the cutting on end portion A is taken from thetop side of the fabric while the cutting on end portion B is taken fromthe bottom side of the fabric. In addition, it is preferred that thecutting of the warp filaments take place from bottom to top, as viewedin FIG. 2.

After the patterns in the end portions A and B are cut, and the shutesare removed, the end portion A (cut from the top side) may then be laidupon a support, such as an assembly table, and held against movementadjacent its cut edge by suitable means, such as a weight. A polymericreplacement shute, such as 26, may then be laid transversely (FIG. 2)across the trough which is formed by the upper surfaces of the innermostbottom warp knuckles in the pickets of warp filaments, lA, 3A, S-A, etc.

Upon placement of the shute filament 26, the end portion B of the fabricmay then be moved into interfitting relationship with the end portion Auntil the cut ends of the corresponding and complementary warp filamentsin each portion abut one another. Such abutment may be assured byperfectly aligning the fabric along one edge. Thus, the end of warpfilament I-A on the portion A abuts the end of the warp filament l-B onthe other portion B of the fabric. Similarly, the ends of warp filaments2-B, 4-B, 6-B, 8-3 and 10-8, abut the ends of warp filaments 2A, 4-A,6-A, 8-A, etc. After the end portions A and B have been broughttogether, the end portion B may also be held against movement on theassembly table as by a second weight. It has been found, for example,that magnetic metals weights laid on the surface of the fabric near theseam area are effective for holding the ends of the fabric during theseaming operation.

After intermeshing the end portions A and B in this manner, additionalreplacement shute filaments of polymeric material are progressivelywoven into place. In the form shown, this may be achieved by handpicking into place a second replacement shute, such as 27, byprogressively lifting the pickets on the end portion A and sliding theshute into place. For example, commencing at the lower side of FIG. 2,the shute filament 27 is picked under warp 1-A, over warp 2-B, underwarp 3-A, over warp 4-B, etc., until the shute is placed beneath all thewarps in the row. Thus positioned, the fabric, including the endportions A and B, may then for convenience be lifted into a generallyvertical position, whereupon, a third polymeric replacement shute, suchas 28, may be hand woven (i.e., picked) into place, but from the bottomside of the fabric. For example, the shute 28 may be picked over warpI-A, under warp 2-B, over warp 3-A, under warp 4-B, etc.,

thereby to complete the row. After the third shute 28 is positioned, afourth polymeric replacement shute filament, such as 29, may then bepicked into place while the fabric is still in the vertical position,but from the top side of the fabric. For example, the picking wouldproceed under warp l-A, over warp 2-B, under warp 3-A, over warp 4-B,etc. Preferably, a fifth polymeric replacement shute, such as 30, maythen be picked into place while the seam area remains in the verticalposition, but from the bottom side of the fabric by picking the shuteover warp l-A, under warp 2B, etc., in the same manner described inconnection with the third shute 28. By this method, an effective seamarea is provided, except for the interlocking joint between thecorresponding cut warps of both end portions, and which may be achievedwithout the need for specially shaped shutes and/or auxiliary drawingtechniques for inserting the shutes into the seam area.

It will be appreciated that the width of the seam area A is actuallyvery narrow as compared to the actual dimensions of the fabric which mayvary dependent on such factors as the size and/or number of shutefilaments employed. In this connection, it will be understood that while5 replacement shute filaments are preferred to provide the seam, a lessnumber, such as 4 or 3, may also be employed, as desired.

In cutting the warp filaments, it is important that a tool, such as athin razor-type blade, narrow enough to fit into the fabric geometry andcut the individual filaments without distorting and/or cutting adjacentfilaments of the fabric to be employed. In addition, the angle andposition of the cut are important to achieve proper abutment of thefilament ends. In the invention, basically two freehand-type cuts may beemployed. In one method (FIG. 6), the cut is made between shutes 31 and40 (previously removed) by slicing through the warp filament, such asl-A, at approximately its midpoint, as at 54, as it slopes upward fromthe bottom toward the top of the fabric and at an angle B, such as 60with respect to a line extending perpendicular to the general plane ofthe fabric. Accordingly, to insure that the mating ends of the warpfilaments will abut flatly against each other, the angle of cut on onefilament preferably supplements the angle of cut on the mating filamentend. In this regard, the cut on the long warp pickets, such as 1-A, 3-A,etc., can also be made by a hand shears by making the cut supplementaryto the angle of cut for the short warp pickets, such as 2A, 4-A, etc.,as aforesaid.

The aforementioned second cut which may be employed may be achieved, asshown in FIG. 7, by placing the cutting tool T (blade edge) at thepoint, such as 52, at which the upper surface of the bottom warp knuckle55, of the warp l-A meets the peripheral surface of the shute filament40. By placing the blade at point 52 from the top side of the fabric,the cut can be made at an angle A of approximately 45 with respect to aline which extends perpendicular to the general plane of the fabric.This provides a cut thro u'glifirewaip fiiament, such as l-A, which ishidden from view when looking from the top side of the fabric.Similarly, the warp filaments which are used for forming the shortpickets on the end A, may be cut in the manner described in connectionwith the formation of the short pickets on end B, and as illustrated ineither FIG. 6 or 7, while the ends of the long pickets on end A are cutat an angle supplementary to that of the short pickets on end A.

Prior to bonding the abutting ends of the warp filaments together, ithas been found that the surfaces of the filaments which comprise theseam and a portion of the body of the fabric on each side of the seammay be treated to enhance their adhesive characteristics. In one method,the surface of the filaments may be roughened by blasting the surfacewith small particles of abrasive material, such as micron-sized siliconcarbide. This method may be carried out following the removal of theshute filaments and after the warp pickets have been cut at their ends.Preferably, both the top and bottom surfaces of the seam are treated inthis manner so that all exposed surfaces of the warps are roughened.This treatment may also be employed after assembly (meshing) of the endportions A and B so as to increase the adhesability of all the filamentsurfaces in the region of the seam and to remove any soil or the likedeposited during the seam assembly. As an alternate method, a suitableelectrical corona discharge treatment may be employed. By either method,it has been found that scam strengths improve by about 25 percent ascompared to seam strengths as derived from adhering untreated seams.

In the invention, the warp filaments and the replacement shute filamentsfor the seam are comprised of a polymeric material. Preferably, suchfilaments are formed of a polyester resin, such as polyethyleneterephthalate. For example, a polyester filament having a diameter of0.032 inch is available from the Goodyear Polyester Products Departmentunder the trade name, VITEL, type VFR 1676, or a 0.025 millimeterpolyester filament available from the American Hoechst Company under thetrade name TRIVERA, or a 0.020 millimeter polyester filament availablefrom the American Hoechst Company under the trade name TRIVERA, type P,may be employed for the warps. For the shute, 0.020 millimeter polyesterfilaments available from the American Hoechst Company under the tradenames TRIVERA, type PR and TRIVERA, type PRN, may be employed. In thecase of semi-polymeric fabrics, such as when metal shutes are employedduring weaving for use in paper making belts, it is preferred that thepolymeric material for the filaments of the seam have a low thermalshrinkage, such as about 1 percent shrinkage by length at a temperatureof about 212 F.

After the end portions A and B of the fabric have been assembled(intermeshed), the abutting ends of the warp filaments are bonded to oneanother. In one form, the bonding may be achieved by the application ofan adhesive by means of a tool, such as a hypodermic syringe needle,which, for example, may have an 0.006 inch ID. and a 0.013 inch OD. Theneedle may be force fed by a micro-metering pump of the type availablefrom the Pyles Equipment Company. In use, the needle may be mounted on asuitable support (not shown) and may be guided along a row of joints inthe seam pickets so as to disperse a metered amount of adhesive toprovide the joints, such as 54, between the free cut ends of the opposedwarp filaments, as seen in FIGS. 1 and 4. The other row of joints, as at56, is similarly treated so that all the joints are filled with theadhesive and without filling the openings in the fabric adjacent thebond.

The adhesive material employed will depend on the materi al of which thewarp and shute filaments are formed to provide a compatible and strongadhesive bond therebetween. For polyester filaments, at least threeclasses of adhesive material have been found to be useful including (1)polyester resin cured with a free radical catalyst, (2) phenoxy resincured with free isocyanate prepolymeris, and (3) vinyl acetate maleicacid ethylene terpolymer cured with urea formaldehyde. The curing agentsor catalysts are added to the resins to cause them to become tough,strong and water resistant after curing. For example, when the warps arepolyester filaments, the adhesive material applied may be equal weightsof a polyester resin (available under the trade name MOBAY R-l2) andtrimethylolpropane adduct of tolylene di-isocyanate (available under thetrade name MOBAY CB-75).

To effect completion of the curing process, the applied adhesive ispreferably heated to a temperature sufiicient to cause a complete curewithin a time period suitably short for production purposes. It ispreferred that the temperature never be equal to or greater than thetemperature employed to thermally stabilize (heat set) the warp picketsprior to cutting thereof. By this method, the seam area remains stablethroughout the adhesive cure so as to insure proper strengthcharacteristics at the joints. Moreover, any thermal movement and/orshrinkage of the pickets during the curing period would disrupt thebonding effect which takes place during the cure. For a polyester typeadhesive material and a preseam thermal treatment at about 200 F., thecure may be carried out at a temperature of about 175 F. and at a timebetween about 3 to 4 hours, for example. The joints may then be allowedto cool or cooled to ambient temperature, as desired.

After the picket joints have been cured and cooled in the manneraforesaid, the entire area of the seam S is then preferably saturatedwith an adhesive material. After saturation of the seam, the excessadhesive material which fills the mesh may be blown off, such as bycompressed air, at about lbs. p.s.i. so that there is provided a thinfilm of material adhering to the exposed surfaces of the filaments. Thisremaining film of material is sufficient to provide a filleting, as at58, around the crossovers of the warp and shute filaments, as seen inFIG. 5. Upon curing of the fillet material, the warp and shute filamentsare further adhered to one another so as to increase the overallstrength of the seam. Such curing of the saturating adhesive may beachieved by the addition of a suitable catalyst of the typesaforementioned and/or by the application of heat at a temperature whichis also applied below the thermal stabilizing (heat set) temperature forthe seam. For example, with a polyester bond adhesive, such as availableunder the trade name MOBAY CB-75, the cure may be carried out at atemperature of about 175 F. for a period of about 3 hours. In curing,there is achieved a cross-linking between the adhesive material for thewarp joints and the saturating adhesive material to provide a strongbond between the warp and shute filaments.

In the invention, the saturating adhesive may be diluted with a solventwhich is appropriate for the resin of which the warp and shute filamentsare formed. For example, when the saturating adhesive is MOBAY CB-75, itmay be diluted with cellosolve acetate to a viscosity of about 0.1poises. The use of the solvent thins the adhesive and facilitatesblowing-out of the mesh openings, particularly as the mesh count persquare inch increases. In the form shown, saturation of the seamfollowing the bonding of the joints prevents movement of the warppickets so as to eliminate geometric discontinuities, thus effecting abetter quality seam.

As a specific example, the invention was carried out by making a 70 by58 mesh fabric of polyester warp and shute filaments which were heat setat 275 F. for 5 minutes. The material for the warp was 0.20 (mm) and0.25 (mm), available under the trade designations as types P No. 087031and PRN No. 017032, respectively, from the American Hoechst Company. Theadhesive for the seam was a mixture in a ratio of 1:] of the trade namematerials MULTRON R-l 2 (polyester) and MONDUR CB-75 (isocyanate),available from the Mobay Chemical Company. This adhesive mixture wascured at a temperature of F. for a period of 18 hours.

By the foregoing method, there is provided a seam which will not yieldor separate in any manner until after the tensile yield strength of thefabric has been surpassed so as to achieve a seam which is especiallysuitable as to durability in tension. Furthermore, it has been foundthat the fatigue life of the seam is comparable to that of the body ofthe fabric, and also that the seam does not mark the paper made upon itto any significant extent.

Accordingly, it will be seen that this method of seaming can be appliedto other forms of weaving other than that illustrated. Similarly, themethod may be applied in making other types of relatively fine meshfabrics and for other purposes.

The terms and expressions which have been used are used as terms ofdescription and not of limitation and there is no intention in the useof such terms and expressions of excluding any equivalents of thefeatures shown or described or portions thereof and it is recognizedthat various modifications may be possible within the scope of theinvention claimed.

I claim:

1. A method for joining together the end portions of a porous, wovenfabric strip having warp and shute filaments to form an endless article,comprising the steps of cutting at least some of the warp filamentsadjacent one of said end portions to different lengths relative to oneanother to form a first set of warp pickets defining a pattern of pointsof warp filament severance,

cutting at least some of the warp filaments adjacent another of said endportions to different lengths relative to one another to form a secondset of warp pickets defining a complementary pattern of points of warpfilament severance,

removing the shute filaments from each of said end portions between therespective points of warp severance and the terminal ends of said endportions,

placing a first replacement shute transversely of and in overlyingrelation to at least some of said warp pickets of said first set of warppickets and in spaced relation adjacent to the remaining original shutefilament nearest the terminal end of said one end portion,

moving both of said end portions together with said second set of warppickets positioned in overlying contact with said first replacementshute and with the ends of said second set of warp pickets positioned inabutting end-toend engagement with the corresponding complementary endsof said first set of warp pickets,

progressively weaving at least one additional replacement shute, one ata time, into transverse relation with relation to the remaining exposedwarp pickets of said first and second sets of warp pickets by,

commencing at a first lateral edge of said fabric and proceeding towarda second lateral edge of said fabric and proceeding toward a secondlateral edge of said fabric,

progressively raising the ends of said warp filaments of said one endportion which extend beyond said first replacement shute filament in adirection toward the terminal end of said one end portion,

commencing at said first lateral edge and inserting a single additionalreplacement shute filament between said raised warp filaments and theremaining warp filaments transversely and progressively across thefabric to the second lateral edge, and

returning the raised warp filament to their initial unraised positionsto recreate and preserve the weave pattern of the remainder of saidfabric.

2. A method according to claim 1, including the additional step of,

inserting another single additional replacement shute filament byprogressively raising said warp filaments of said one end in a directionopposite to the direction raised for inserting said single additionalreplacement shute filament 3. A method according to claim 2, includingweaving still further replacement shute filaments, one at a time untilthe number of replacement shute filaments equals the number of shutefilaments removed from said one end portion of said fabric.

4. A method according to claim 6, wherein at least the end portions ofthe fabric are heat set prior to the joining together of the endportions of the fabric.

5. A method according to claim 1, wherein said shute filaments are madeof a metallic material.

6. A method according to claim 1, wherein said warp filaments comprise apolyester material.

7. A method according to claim 6, wherein at least the end portions ofsaid warp filaments are heat set at a temperature of about 200 F. for aduration of about minutes prior to joining together the end portions ofthe fabric.

8. A method according to claim 1, wherein said shute filaments are madeof a polymeric material.

9. A method according to claim 1, wherein the cutting on one of said endportions is taken from the top surface of said fabric, and

the cutting on another of said end portions is taken from the bottomsurface of said fabric.

10. A method according to claim 1 wherein said additional replacementshute filaments are woven from alternate surfaces of said fabric.

1 l. A method according to claim 1, wherein each end portion during saidcutting steps is cut with the distance between the respective endportion of the fabric and the farthest point of warp severance beingabout five shute filament spacings,

five shute filaments are removed, and

five replacement shute filaments are woven into said fabric.

12, A method according to claim 1, wherein said some warp filaments ofat least one of said end portions are cut across the filaments at apoint on each filament between adjacent shute-warp crossings.

13. A method according to claim 12, wherein said some warp filaments ofat least one of said end portions are cut at an angle of about 60 withrespect to a line extending perpendicular to the general plane of thefabric.

14. A method according to claim 1, wherein said some warp filaments ofat least one of said end portions are cut across the filaments adjacenta point on each of said filaments at which the warp filament contactsthe peripheral surface of a shute filament.

15. A method according to claim 14, wherein said some warp filaments arecut at an angle of about 45 with respect to a line extendingperpendicular to the general plane of the fabric.

16. A method according to claim 1, wherein said some of said warpfilaments are angularly cut, and

the cut warp filaments adjacent one end portion are cut at an anglewhich is the supplement of the angle at which the cut warp filamentsadjacent the other end portion are cut.

17. A method according to claim 1, wherein,

adhesive material is applied to the warp and weft filaments in theregion of the seam in sufficient quantity to fill the intersticesbetween the warp and weft filaments which comprise the seam and aportion of the body of the fabric on each side of the seam, and whereinexcess adhesive material is pneumatically removed from the filaments.

18. A method in accordance with claim 1, including,

the step of increasing the adherability of the warp picket filamentsurfaces to the adhesive prior to the application of adhesive materialthereto.

19. A method in accordance with claim 18, wherein said surfaces areblasted with abrasive particles.

20. A method in accordance with claim 18, wherein said surfaces aresubjected to electrical corona discharge treatment.

21. A method according to claim 1, wherein said replacement shutefilaments have a maximum thermal shrinkage of about l shrinkage bylength when subjected to a temperature of about 212 F.

22. A method according to claim 1, wherein adhesive material is appliedto the joints between free cut ends of opposed warp filaments withoutsubstantially filling spaces between adjacent shute filaments andbetween adjacent warp filaments,

23. A method according to claim 22, wherein additional adhesive materialis applied to the warp and weft filaments in the region of the seam insufficient quantity to fill the interstices between the warp and weftfilaments which comprise the seam and a portion of the body of thefabric on each side of the seam, and wherein excess adhesive material ispneumatically removed from the filaments.

24. A method according to claim 22, wherein at least the end portions ofthe fabric are heat set prior to the joining together of the endportions of the fabric, and

said adhesive material is cured at a temperature below the temperatureat which said end portions are heat set.

2. A method according to claim 1, including the additional step of,inserting another single additional replacement shute filament byprogressively raising said warp filaments of said one end in a directionopposite to the direction raised for inserting said single additionalreplacement shute filament
 3. A method according to claim 2, includingweaving still further replacement shute filaments, one at a time untilthe number of replacement shute filaments equals the number of shutefilaments removed from said one end portion of said fabric.
 4. A methodaccording to claim 6, wherein at least the end portions of the fabricare heat set prior to the joining together of the end portions of thefabric.
 5. A method according to claim 1, wherein said shute filamentsare made of a metallic material.
 6. A method according to claim 1,wherein said warp filaments comprise a polyester material.
 7. A methodaccording to claim 6, wherein at least the end portions of said warpfilaments are heat set at a temperature of about 200* F. for a durationof about 20 minutes prior to joining together the end portions of thefabric.
 8. A method according to claim 1, wherein said shute filamentsare made of a polymeric material.
 9. A method according to claim 1,wherein the cutting on one of said end portions is taken from the topsurface of said fabric, and the cutting on another of said end portionsis taken from the bottom surface of said fabric.
 10. A method accordingto claim 1 wherein said additional replacement shute filaments are wovenfrom alternate surfaces of said fabric.
 11. A method according to claim1, wherein each end portion during said cutting steps is cut with thedistance between the respective end portion of the fabric and thefarthest point of warp severance being about five shute filamentspacings, five shute filaments are removed, and five replacement shutefilaments are woven into said fabric.
 12. A method according to claim 1,wherein said some warp filaments of at least one of said end portionsare cut across the filaments at a point on each filament betweenadjacent shute-warp crossings.
 13. A method according to claim 12,wherein said some warp filaments of at least one of said end portionsare cut at an angle of about 60* with respect to a line extendingperpendicular to the general plane of the fabric.
 14. A method accordingto claim 1, wherein said some warp filaments of at least one of said endportions are cut across the filaments adjacent a point on each of saidfilaments at which the warp filament contacts the peripheral surface ofa shute Filament.
 15. A method according to claim 14, wherein said somewarp filaments are cut at an angle of about 45* with respect to a lineextending perpendicular to the general plane of the fabric.
 16. A methodaccording to claim 1, wherein said some of said warp filaments areangularly cut, and the cut warp filaments adjacent one end portion arecut at an angle which is the supplement of the angle at which the cutwarp filaments adjacent the other end portion are cut.
 17. A methodaccording to claim 1, wherein, adhesive material is applied to the warpand weft filaments in the region of the seam in sufficient quantity tofill the interstices between the warp and weft filaments which comprisethe seam and a portion of the body of the fabric on each side of theseam, and wherein excess adhesive material is pneumatically removed fromthe filaments.
 18. A method in accordance with claim 1, including, thestep of increasing the adherability of the warp picket filament surfacesto the adhesive prior to the application of adhesive material thereto.19. A method in accordance with claim 18, wherein said surfaces areblasted with abrasive particles.
 20. A method in accordance with claim18, wherein said surfaces are subjected to electrical corona dischargetreatment.
 21. A method according to claim 1, wherein said replacementshute filaments have a maximum thermal shrinkage of about 1* shrinkageby length when subjected to a temperature of about 212* F.
 22. A methodaccording to claim 1, wherein adhesive material is applied to the jointsbetween free cut ends of opposed warp filaments without substantiallyfilling spaces between adjacent shute filaments and between adjacentwarp filaments.
 23. A method according to claim 22, wherein additionaladhesive material is applied to the warp and weft filaments in theregion of the seam in sufficient quantity to fill the intersticesbetween the warp and weft filaments which comprise the seam and aportion of the body of the fabric on each side of the seam, and whereinexcess adhesive material is pneumatically removed from the filaments.24. A method according to claim 22, wherein at least the end portions ofthe fabric are heat set prior to the joining together of the endportions of the fabric, and said adhesive material is cured at atemperature below the temperature at which said end portions are heatset.